Comparison, co-existence and interoperability of heterogeneous IEC 61499 control systems

Abstract

Industry 4.0 has gained significant traction across manufacturing and process industries, driving the transformation of traditional automation systems into more intelligent, flexible, and decentralized control architectures. As a result, the IEC~61499 standard has attracted considerable attention, as it aligns with the core motivations of Industry 4.0 by providing a foundation for developing vendor-independent and heterogeneous distributed automation solutions. Over the past decade, several software tools and control devices compliant with this standard have emerged, each utilizing different runtime environments. This thesis explores the interoperability and co-existence of heterogeneous control systems developed using two such tools: Neptune Function Block Builder (NFBB) and EcoStruxure Automation Expert (EAE).

The study starts with a comprehensive comparison between NFBB and EAE in terms of their software architecture, runtime environments (FBSRT and UAO respectively), usability, and support for IEC~61499 compliance profiles. EAE, as a mature commercial tool, offers advanced features and broad vendor interoperability. In contrast, NFBB introduces a modern web-based interface with multi-language programming support. Despite architectural differences, both tools demonstrated basic portability through the exchange of function blocks in XML format with minimal modifications.

To validate their capabilities, both tools were applied in practical implementations on an automotive assembly demonstrator. Each tool was used to develop an independent control solution using its respective hardware controllers. Additionally, the study demonstrated system co-existence by allowing both applications to run on the same physical setup with seamless switching. Interoperability between the two systems was successfully achieved using OPC UA communication, enabling cross-platform control.

This work highlights the practical viability of integrating heterogeneous IEC~61499 systems and provides valuable insights into the strengths and limitations of emerging and established development tools.